Voltage Regulator Leroy Somer r438 Avr Voltage Regulator Leroy Somer r438 Avr

This manual is to be given to

the end user

3971 en - 11.2006 / c

R438

A.V.R.

Installation and maintenance

X2 X1 Z2 E+ E- 0V 110 220Z1

6-

R 438

1

T350Hz 60Hz

T5

T10LAM 13 %

Field

Armature

10 Yellow

11 Red

9 Green

12 Black

Slow fuse 250V 8 A

quency

with LAM without LAM

3971c_NotRegR438_en.fm Jeudi, 9. novembre 2006 10:13 10


R438

A.V.R.

2

3971 en - 11.2006 / c

LEROY-SOMER

SAFETY MEASURES

Before using your machine for the first time,it is important to read the whole of thisinstallation and maintenance manual.

All necessary operations and interventionson this machine must be performed by aqualified technician.

Our technical support service will bepleased to provide any additional infor-mation you may require.

The various operations described in thismanual are accompanied by recommen-dations or symbols to alert the user topotential risks of accidents. It is vital thatyou understand and take notice of thefollowing warning symbols.

This A.V.R. can be incorporated in amachine marked C.E.

Warning symbol for an operationcapable of damaging or destroying themachine or surround-ing equipment.

Warning symbol for general danger topersonnel.

Warning symbol for electrical danger topersonnel.

Note: LEROY-SOMER reserves the right tomodify the characteristics of its products atany time in order to incorporate the latesttechnological developments. The informationcontained in this document may therefore bechanged without notice.

WARNINGWARNING

This manual concerns the alternator A.V.R. which you have just purchased.

We wish to draw your attention to the contents of this maintenance manual. Byfollowing certain important points during installation, use and servicing of your A.V.R.,you can look forward to many years of trouble-free operation.



R438

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3

CONTENTS

1 - SUPPLY .............................................................................................................................4

1.1 - AREP excitation system ..............................................................................................41.2 - PMG excitation system................................................................................................51.3 - SHUNT or separate excitation system.........................................................................5

2 - R438 A.V.R. .......................................................................................................................6

2.1 - Characteristics .............................................................................................................62.2 - Frequency compared with voltage (without LAM)........................................................62.3 - LAM (Load Acceptance Module) characteristics .........................................................62.4 - Typical effects of the LAM with a diesel engine with or without a LAM (U/F only).......72.5 - R438 A.V.R. options ....................................................................................................7

3 - INSTALLATION - COMMISSIONING................................................................................8

3.1 - Electrical checks on the AVR.......................................................................................83.2 - Settings........................................................................................................................83.3 - Electrical faults...........................................................................................................11

4 - SPARE PARTS................................................................................................................12

4.1 - Designation................................................................................................................124.2 - Technical support service ..........................................................................................12

All such operations performed on the A.V.R. should be undertaken by personnel trainedin the commissioning, servicing and maintenance of electrical and mechanicalcomponents.

Copyright 2005 : MOTEURS LEROY-SOMERThis document is the property of :MOTEURS LEROY-SOMERIt may not be reproduced in any form without prior authorization. All brands and models have been registered and patents applied for.


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R438

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1 - SUPPLY1.1 - AREP excitation system

For both AREP & PMG excitation systems,the alternator voltage regulator is the R438.With

AREP

excitation, the R438 electronicAVR is powered by two auxiliary windingswhich are independent of the voltagematch circuit.The first winding has a voltage in proportion

to that of the alternator (characteristicShunt), the second has a voltage inproportion to the stator current (compoundcharacteristic: Booster effect).The power supply voltage is rectified andfiltered before being used by the AVRmonitoring transistor. This principleensures that regulation is not affected bydistortions generated by the load.

4 x holes Ø 5.8 x 175 x 115 mm

200

mm

140 mm

X2 X1 Z2 E+ E- 0V 110 220 380Z1

T1 T2 T3

T4 T5 T6

Var

isto

r

5+ 6-

T7 T8 T9

T10 T11 T12

R 438

F1

ST350Hz 60Hz

ST5

ST10LAM 13 %

LAM 25 %

P5

ST11

ST2 ST1

P3

P2

P1

ST4

ST9

Option

AREP

PMG PMG

T.I. Option

S1 P1Ph.1

P2S2

R731

Option

AREP SYSTEM

Field

Armature

10 Yellow

11 Red

9 Green

12 Black

MAIN FIELD Aux. windings

Slow fuse 250V 8 A

Frequency


Excitationceiling

knee-point: 65 Hz open

Responsetime

normalfast

StabilityVoltage Single-

phasedetection

External potentiometerfor adjusting the voltage

Quaddroop

according voltage

STATOR : 6 wires (marked T1 to T6)STATOR : 12 wires (marked T1 to T12)

in 3-ph. detection ST1 open

3-ph. detection


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1.2 - PMG excitation system

This excitation system consists of a "

PMG

"(permanent magnet generator). This isfitted at the rear of the machine andconnected to the R438 AVR.The PMG supplies the AVR with constantvoltage which is independent of the main

alternator winding. As a result the machinehas a short-circuit current capacity andgood immunity to distortions generated bythe load.The AVR monitors and corrects thealternator output voltage by adjusting theexcitation current.- 50/60 Hz selection via the

ST3

jumper.

1.3 - SHUNT or separate excitation system

A.V.R. can be operated with SHUNT supply (with a transformer / secondary 50V or a 48Vbattery).

4 x holes Ø 5.8 x 175 x 115 mm

200

mm

140 mm

X2 X1 Z2 E+ E- 0V 110 220 380Z1

T1 T2 T3

T4 T5 T6V

aris

tor

5+ 6-

T7 T8 T9

T10 T11 T12

R 438

F1

ST350Hz 60Hz

ST5

ST10LAM 13 %

LAM 25 %

P5

ST11

ST2 ST1

P3

P2

P1

ST4

ST9

Option

AREP PMG

14 15 16

PMG

T.I. Option

S1 P1Ph.1

P2S2

R731

Option

PMG SYSTEM

Field

Armature

MAIN FIELD

Slow fuse 250V 8 A

Frequency


Excitationceiling

knee-point: 65 Hz open

Responsetime

normalfast

StabilityVoltage Single-

phasedetection

External potentiometerfor adjusting the voltage

Quaddroop

according voltage

STATOR : 6 wires (marked T1 to T6)STATOR : 12 wires (marked T1 to T12)

in 3-ph. detection ST1 open

3-ph. detection



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2 - R438 A.V.R. 2.1 - Characteristics

- Standard power supply: AREP or PMG.- Rated overload current: 8 A - 10 s- Electronic protection (overload, short-circuit on opening of voltage sensingcircuit): excitation overload current for 10seconds then return to approximately 1A.The alternator must be stopped (or thepower switched off) in order to reset theprotection.- Fuse : F1 on X1, X2. 8A ; slow - 250V- Voltage sensing : 5 VA isolated viatransformer ;• 0-110 V terminals = 95 to 140 V,• 0-220 V terminals = 170 to 260 V,• 0-380 V terminals = 340 to 520 V.- Voltage regulation ± 1%.- Normal or rapid response time via

ST2

jumper (see below).- Voltage adjustment via potentiometer

P2

. other voltages via adapter transformer- Current sensing (parallel operation): C.T.2.5 VA cl1, secondary 1 A (optional).- Quadrature droop adjustment viapotentiometer

P1

.- Max. excitation current adjustment via

P5

(see below).

2.1.1 -

Configuration jumpers function

2.1.2 -

Setting potentiometers function

2.2 - Frequency compared with voltage (without LAM)

2.3 - LAM (Load Acceptance Module) characteristics

2.3.1 - Voltage drop

The LAM system is integrated in the R 438AVR as standard.Role of the "LAM" (Load AdjustmentModule) :On application of a load, the rotation speedof the generator set decreases. When itpasses below the preset frequencythreshold, the LAM causes the voltage todrop by approximately 13% or 25% andconsequently the amount of active loadapplied is reduced by approximately 25%to 50%, until the speed reaches its ratedvalue again.Hence the LAM can be used either toreduce the speed variation (frequency) andits duration for a given applied load, or toincrease the applied load possible for onespeed variation (turbo-charged engine).To avoid voltage oscillations, the tripthreshold for the LAM function should beset approximately 2 Hz below the lowestfrequency in steady state.

Pot.Delivreryconfig. Position Function

Open Closed

ST1 3-ph. MonoOpen for moduleinstallation tri detection

ST2 Fast Normal Response time

ST3 50 ou 60 Hz Frequency selection

ST4Externalpotentio-

meterWithout Potentiometer

ST5 Without With LAM

ST9Others

(PMG...)AREP Supply

ST10 13% or 25%LAM voltage dropamplitude

ST11 65 Hz48 or 58 Hz

U/f function bendposition

Delivreryposition Pot. Function

0 P1 Quadrature droop ; // operation with C.T.

400V P2 Voltage

Centre P3 Stability

Maxi P5 Excitation current ceiling

100 %

50 Hz 60 Hz Hz

50 Hz

48 Hz57.5 Hz

60 Hz

Voltage Bend

U/UN

Frequency


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R438

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- LAM : action eliminated by cutting the ST5jumper.

2.3.2 - Gradual voltage return function

During load impacts, the function helps thegenset to return to its rated speed fasterthanks to a gradual increase in voltageaccording to the principle:- If the speed drops between 46 and 50 Hz,the rated voltage follows a fast gradient asit is restored.- If the speed drops below 46 Hz, since theengine needs more help, the voltagefollows a slow gradient as it returns to thereference value.

2.4 - Typical effects of the LAM with a diesel engine with or without a LAM (U/F only)

2.4.1 - Voltage

2.4.2 - Frequency

2.4.3 - Power

2.5 - R438 A.V.R. options

-

Current transformer

for parallel operationof ....../1A. 5 VA CL 1. -

Remote voltage adjustment

potentiometer

:470

Ω

, 0.5 W min: adjustment range ± 5%(range limited by internal voltagepotentiometer

P2

). Remove ST4 to connectthe poten-tiometer. (A 1 k

Ω

potentiometercan also be used to extend the adjustmentrange).-

R 731 external module

: sensing of 3-phase voltage 200 to 500 V, compatible withparallel operation. Disconnect ST1 toconnect the module; set the voltage via themodule potentiometer.

- R 734 module

: detection of 3-phasecurrent and voltage for parallel operation onunbalanced installations (imbalance > 15%).-

R 726 module

: 3 functions (mountedexternally)P.F. regulation (2F) and voltage sensingcircuit before paralleling (3 F).

- Control through DC voltage

usedmonitoring apply to the terminals forconnection of a potentiometer DC voltage :• internal impedance 1,5 k

Ω

• ± 0,5V enable a voltage setting of 10%.

LAM

UN

048 or 57.5 Hz

0.85 UN

Voltage

U/f

50 or 60 Hz

fC fN

VoltageST5 disconnected

ST3

P2

Underspeed and LAM

0Time

Drop N ≤ 46 Hz

U

Drop N > 46 Hz

UN

0

0,9

0,8

(U/f)

with LAM Time

without LAM

1 s 2 s 3 s

Transient voltage drop

0,9

0,8

fN Max speed drop

0

with LAM

Time

without LAM

1 s 2 s 3 s

0 1 s 2 s 3 sTime

LAM

Variation in the load L

oad

on

th

esh

aft

(kW

)Load shedding due to "LAM"



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LEROY-SOMER

3 - INSTALLATION - COMMISSIONING3.1 - Electrical checks on the AVR

- Check that all connections have beenmade properly as shown in the attachedwiring diagram.- Check that the ST3 frequency selectionjumper is on the correct frequency setting.- Check whether the ST4 jumper or theremote adjustment potentiometer havebeen connected.- Optional operating modes. • ST1 jumper : open to connect the R731or R 734 3-phase sensing module. • ST2 jumper : open if rapid response timeused • ST5 jumper : open to suppress the LAMfunction.

3.2 - Settings

The machine is tested and set at thefactory. When first used with no load,make sure that the drive speed iscorrect and stable (see the nameplate).After operational testing, replace allaccess panels or covers.The only possible adjustments to themachine should be made on the AVR.

3.2.1 - R438 settings (AREP or PMG system)

Before any intervention on the A.V.R.,make sure that the ST9 jumper is closedwith AREP excitation and disconnectedwith PMG or SHUNT or separateexcitation.

a)

Initial potentiometer settings (see tablebelow)- Remote voltage adjustment potentiometer :centre (ST4 jumper removed).

Stability adjustments in standaloneoperation

b

) Install a D.C. analogue voltmeter(needle dial) cal. 50V on terminals E+, E-and an A.C. voltmeter cal 300 - 500 or1000V on the alternator output terminals.

c

) Make sure that the

ST3

jumper ispositioned on the desired frequency (50 or60 Hz).

d

) Voltage potentiometer

P2

at minimum,fully anti-clockwise.

e

) Stability potentiometer

P3

to around 1/3of the anti-clockwise limit.

f

) Start the engine and set its speed to afrequency of 48 Hz for 50 Hz, or 58 for 60Hz.

g

) Set the output voltage to the desiredvalue using

P2

.- Rated voltage UN for solo operation (eg.400 V)- Or UN + 2 to 4% for parallel operation withC.T. (eg. 410 V) If the voltage oscillates, use P3 to makeadjustments (try both directions) observing

WARNINGWARNING

P2

P3

P1

P5 10 A

maximum

400V - 50 Hz (Input 0 - 380 V)

Not set(centre position)

Not set(fully anti-clockwise)

Excitation ceilingLimit of excitation andshort-circuit current, minimum fully anti-clockwise.

Voltage quadrature droop(// operation with C.T.)- 0 quadrature loop fullyanti-clockwise.

Voltageminimum fully anti-clockwise

Stability

Action Factory setting Pot.



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the voltage between E+ and E- (approx.10V D.C.). The best response times areobtained at the limit of the instability. If nostable position can be obtained, trydisconnecting or replacing the ST2 jumper(normal/fast).

h

) Check LAM operation :

ST5

closed.

i)

Vary the frequency (speed) around 48 or58 Hz according to the operatingfrequency, and check the change in voltagefrom that observed previously (~ 15%).

j

) Readjust the speed of the unit to its ratedno-load value.Adjustments in parallel operation

Before any intervention on thealternator, make sure that the speeddroop is identical for all engines

.

k

) Preset for parallel operation (with C.T.connected to S1, S2)- Potentiometer P1 (quadrature droop) incentre position.Apply the rated load (cos

ϕ

= 0.8 inductive).The voltage should drop by 2 to 3%. If itincreases, check that V and W and also S1and S2 have not been reversed.

l

) The no-load voltages should be identicalfor all the alternators intended to run inparallel.- Couple the machines in parallel.- By adjusting the

speed

, try to obtain

0 KW

power exchange.- By altering the voltage setting P2 on oneof the machines, try to cancel (or minimise)

the current

circulating between themachines.- From now on, do not touch the voltagesettings.

m

) Apply the available load (the setting is onlycorrect if a

reactive

load is available)- By altering the

speed

, match the

kW

(ordivide the rated power of the unitsproportionally)- By altering the quadrature drooppotentiometer

P1

, match or divide the

currents

.

3.2.2 - Max. excitation setting (excitation ceiling)

Static adjustment of the current limit,potentiometer P5 (factory setting: 7.5 A,fuse rating: 8 A - 10 seconds).The maximum factory setting correspondsto that of the excitation current required toobtain a 3-phase short-circuit current ofapproximately 3 IN at 50 Hz for industrialpower, unless otherwise specified(*).A static method can be used to reduce thisvalue or adapt the Isc to the actualoperating power (derated machine), whichis safer for the alternator and theinstallation. Disconnect power supply wiresX1,X2 and Z1,Z2 and the voltage reference(0-110V-220V-380V) on the alternator.Connect the mains power supply using atransformer (200-240V) as indicated(X1,X2 : 48V). Install a 10A D.C. ammeterin series with the exciter field. Turn P5 fullyanti-clockwise and activate the powersupply. If there is no output current from theAVR, turn potentiometer P2 (voltage)clockwise until the ammeter indicates astable current. Switch the power supply off,then on again, turn P5 clockwise until therequired max. current is obtained (no morethan 8 A).

Checking the internal protection

:Open switch (D) : the excitation currentshould increase to its preset ceiling, remainat that level for

≥

10 seconds and then dropto < 1A.

Depending onthe mains frequency

Main(50/60 Hz supply)Max. excitation

Voltage

Field~ 5 ohms

X2Z1X1Z2E+E-0V

110 V220 V380 V

50Hz 60Hz

P2

P3

P5

ST3

10 A CC/DC

48 V

110/220/380 V

R 438

ST4

A+–

A

D



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To reset, switch off the power supply byopening switch (A).Note: After setting the excitation ceiling asdescribed, adjust the voltage again (seesection 2.1.1)(*) In some countries it is a legalrequirement to have a short-circuit currentof 3 I

N

, so as to offer selective protection.

3.2.3 - Special type of use

Excitation circuit E+, E- must not be leftopen when the machine is running :AVR damage will occur.

3.2.3.1 - R438 field weakening (SHUNT)

The exciter is switched off by disconnectingthe AVR power supply (1 wire - X1 or X2).Contact rating 16 A - 250V A.C.

3.2.3.2 - R438 field weakening (AREP/PMG)

The exciter is switched off by disconnectingthe AVR power supply (1 wire on eachauxiliary winding) - contact rating 16 A -250V A.C.

Connection is identical for resetting theAVR internal protection.

In case of using the de-excitation,provide a forced excitation.

3.2.3.3 - R438 field forcing

WARNINGWARNING

X2Z1X1Z2E+E-

X2 Z1 X1 Z2 E+ E-

Applications B volts Time t

Guaranteed voltage build-up 12 (1A) 1 - 2 s

Parallel operation, de-energized 12 (1A) 1 - 2 s

Parallel operation, at standstill 24 (2A) 5 - 10 s

Frequency starting 48 (4A) 5 - 10 s

Sustained voltage on overload 48 (4A) 5 - 10 s

X2Z1X1Z2E+E-

Battery (B Volt)

+-t

(400V - 10A)

Exciter field

Diode

t

B Volt

Forced excitation

Time



R438A.V.R.

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11

3.3 - Electrical faults

Warning : after operational testing,replace all access panels or covers.

Fault Action Effect Check/Cause

No voltage at no load on start-up

Connect a new battery of 4 to 12 volts to terminals E- and E+, respecting the polarity, for 2 to 3 seconds

The alternator builds up and its voltage is still correct when the battery is removed.

- Lack of residual magnetism

The alternator builds up but its voltage does not reach the rated value when the battery is removed.

- Check the connection of the voltage reference to the AVR- Faulty diodes- Armature short-circuit

The alternator builds up but its voltage disappears when the battery is removed

- Faulty AVR- Field windings disconnected- Main field winding open circuit - check the resistance

Voltage too low

Check the drive speedCorrect speed

Check the AVR connections (AVR may be faulty)- Field windings short-circuited- Rotating diodes burnt out- Main field winding short-circuited - Check the resistance

Speed too lowIncrease the drive speed(Do not touch the AVR voltage pot. (P2) before running at the correct speed.)

Voltage too high

Adjust AVR voltage potentiometer

Adjustment ineffective Faulty AVR

Voltage oscillations

Adjust AVR stability potentiometer

If no effect : try normal / fast recovery modes (ST2)

- Check the speed : possibility of cyclic irregularity - Loose connections- Faulty AVR- Speed too low when on load (or U/F bend set too high)

Voltage correct at no load and too low when on load (*)

Run at no load and check the voltage between E+ and E- on the AVR

Voltage between E+ and E- SHUNT < 20 V - AREP / PMG < 10V

- Check the speed (or U/F bend set too high)

Voltage between E+ and E- SHUNT > 30V - AREP / PMG > 15V

- Faulty rotating diodes- Short-circuit in the main field. Check the resistance- Faulty exciter armature.

(*) Caution : For single-phase operation, check that the sensing wires coming from the AVR are correctly connected to the operating terminals

Voltage disappears during operation (**)

Check the AVR, the surge suppressor, the rotating diodes, and replace any defective components

The voltage does not return to the rated value.

- Exciter winding open circuit- Faulty exciter armature- Faulty AVR- Main field open circuit or short-circuited

(**) Caution : Internal protection may be activated (overload, open circuit, short-circuit)



R438A.V.R.

12


4 - SPARE PARTS4.1 - Designation

4.2 - Technical support serviceOur technical support service will be happyto provide any information you require.

When ordering spare parts, you should in-dicate the complete machine type, its serialnumber and the information indicated onthe nameplate.

Part numbers should be identified fromthe exploded views and their descriptionin the parts list.Our extensive network of "service stations"can dispatch the necessary parts withoutdelay.To ensure correct operation and the safetyof our machines, we recommend the use oforiginal manufacture spare parts.In the event of failure to comply with this ad-vice, the manufacturer cannot be held res-ponsible for any damage.

Description Type Code

A.V.R. R 438 AEM 110 RE 017



R438NOTES


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R438NOTES

14




R438NOTES


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MOTEURS LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE

338 567 258 RCS ANGOULÊMES.A. au capital de 62 779 000 €

www.leroy-somer.com


Voltage Regulator Leroy Somer r438 Avr Voltage Regulator Leroy Somer r438 Avr

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